Floppy clutch lever? - SV650.org

Geodude · 16-10-22, 12:15 PM

Taking a break from banging my head against wall so thought i'd ask the cleverer people if they have any info on this...

SV650N 99 won't keep clutch adjustment.. Clutch plates, steels and cable all new 500 miles 'ish and worked well until now. New oil today also and at correct level.

1#Lever end loose floppy (f'nar) so do full correct adjustment as per bibs and sids clutch mantra guide. Cable both ends and wormdrive set and perfect. Put bike in 1st lovely, ride forward a bit, nice then flick beautifully into neutral.

2#Let clutch lever out then pull back in put into 1st and clunk bike trying to pull away with clutch fully pulled in and having to hold it back with front brake and no chance of getting neutral with engine running. Wtf?

Roll bike back to garage re-adjust cable wormdrive yadda yadda yadda everything locked down and perfect and repeat 1# and 2# until you start banging your head on wall...

Anybody got any ideas?

As usual i'm pulled in 75 dirrections so if i don't get back to any reply for a bit thats why, not because i think you're an ....

Geodude · 16-10-22, 12:27 PM

Ps i haven't pulled the clutch plates out yet to check if they are stuck together or whatever

Biker Biggles · 16-10-22, 07:41 PM

If you need to readjust so soon then something must be unadjusting itself. IE something is moving that shouldnt be.Lock nuts not locking or the worm drive is fubared allowing it to collapse a bit under load?

Geodude · 17-10-22, 06:25 AM

Hmm worth a look as it sounds possible. How do i separate the worm drive to check its condition and ball count? Also, what size ball bearings if i find any missing?

garynortheast · 17-10-22, 08:04 AM

If it's at the point of needing ball bearings replacing Geo, it's time for a new worm drive.

johnnyrod · 17-10-22, 08:48 PM

Is the cable moving freely enough? My old 99 always had an unpredictable clutch, not a lot but enough.

johnnyrod · 17-10-22, 08:48 PM

Also Gary might be right, the worms last about 20k then they are pretty knackered

Geodude · 18-10-22, 05:44 AM

I've ordered a new (overpriced) worm drive as i have no idea how many miles are on the old one fitted as i bought it second hand some time ago. Thanks for advice lads, appreciated as always. Will let you know when it arrives and is fitted.
Cable moving and routed right and when disconnected at each end i can move the inner easily with my (weak) fingers.

R1ffR4ff · 21-10-22, 12:32 PM

Quote:

Originally Posted by Geodude

I've ordered a new (overpriced) worm drive as i have no idea how many miles are on the old one fitted as i bought it second hand some time ago. Thanks for advice lads, appreciated as always. Will let you know when it arrives and is fitted.
Cable moving and routed right and when disconnected at each end i can move the inner easily with my (weak) fingers.

Have a read here as well,

https://halnico.com/SV650/Clutch/SV650ClutchLifter.html

HTH

Geodude · 23-10-22, 06:44 AM

Thanks for the link very useful ta

16-10-22, 12:15 PM	#1
Geodude Member Mega Poster Join Date: Jun 2009 Location: Durham Posts: 2,669	Floppy clutch lever? Taking a break from banging my head against wall so thought i'd ask the cleverer people if they have any info on this... SV650N 99 won't keep clutch adjustment.. Clutch plates, steels and cable all new 500 miles 'ish and worked well until now. New oil today also and at correct level. 1#Lever end loose floppy (f'nar) so do full correct adjustment as per bibs and sids clutch mantra guide. Cable both ends and wormdrive set and perfect. Put bike in 1st lovely, ride forward a bit, nice then flick beautifully into neutral. 2#Let clutch lever out then pull back in put into 1st and clunk bike trying to pull away with clutch fully pulled in and having to hold it back with front brake and no chance of getting neutral with engine running. Wtf? Roll bike back to garage re-adjust cable wormdrive yadda yadda yadda everything locked down and perfect and repeat 1# and 2# until you start banging your head on wall... Anybody got any ideas? As usual i'm pulled in 75 dirrections so if i don't get back to any reply for a bit thats why, not because i think you're an .... __________________ Black naked 1999 sv650 which im trying to keep happy Custom paintwork *Saragon Customs* Spray painting *Electrical fault finding guide* and *Regulator rectifier test* Only a biker knows why a dog sticks his head out of a car window. Last edited by Geodude; 16-10-22 at 02:35 PM. Reason: Brain hurts

16-10-22, 12:27 PM	#2
Geodude Member Mega Poster Join Date: Jun 2009 Location: Durham Posts: 2,669	Re: Floppy clutch lever? Ps i haven't pulled the clutch plates out yet to check if they are stuck together or whatever __________________ Black naked 1999 sv650 which im trying to keep happy Custom paintwork *Saragon Customs* Spray painting *Electrical fault finding guide* and *Regulator rectifier test* Only a biker knows why a dog sticks his head out of a car window.

16-10-22, 07:41 PM	#3
Biker Biggles Member Mega Poster Join Date: Jan 2005 Location: Barnet Herts Posts: 5,068	Re: Floppy clutch lever? If you need to readjust so soon then something must be unadjusting itself. IE something is moving that shouldnt be.Lock nuts not locking or the worm drive is fubared allowing it to collapse a bit under load? __________________ On a clear day we stand there and look further than the ordinary eye can see.

17-10-22, 06:25 AM	#4
Geodude Member Mega Poster Join Date: Jun 2009 Location: Durham Posts: 2,669	Re: Floppy clutch lever? Hmm worth a look as it sounds possible. How do i separate the worm drive to check its condition and ball count? Also, what size ball bearings if i find any missing? __________________ Black naked 1999 sv650 which im trying to keep happy Custom paintwork *Saragon Customs* Spray painting *Electrical fault finding guide* and *Regulator rectifier test* Only a biker knows why a dog sticks his head out of a car window.

17-10-22, 08:04 AM	#5
garynortheast Member Mega Poster Join Date: Mar 2010 Location: Mid Wales Posts: 2,488	Re: Floppy clutch lever? If it's at the point of needing ball bearings replacing Geo, it's time for a new worm drive. __________________ http://www.teulu-cymru.org/cartref.html https://teulu.bandcamp.com/releases

17-10-22, 08:48 PM	#6
johnnyrod Member Mega Poster Join Date: Jul 2003 Location: Doncaster, oop norf Posts: 2,122	Re: Floppy clutch lever? Is the cable moving freely enough? My old 99 always had an unpredictable clutch, not a lot but enough.

17-10-22, 08:48 PM	#7
johnnyrod Member Mega Poster Join Date: Jul 2003 Location: Doncaster, oop norf Posts: 2,122	Re: Floppy clutch lever? Also Gary might be right, the worms last about 20k then they are pretty knackered

18-10-22, 05:44 AM	#8
Geodude Member Mega Poster Join Date: Jun 2009 Location: Durham Posts: 2,669	Re: Floppy clutch lever? I've ordered a new (overpriced) worm drive as i have no idea how many miles are on the old one fitted as i bought it second hand some time ago. Thanks for advice lads, appreciated as always. Will let you know when it arrives and is fitted. Cable moving and routed right and when disconnected at each end i can move the inner easily with my (weak) fingers. __________________ Black naked 1999 sv650 which im trying to keep happy Custom paintwork *Saragon Customs* Spray painting *Electrical fault finding guide* and *Regulator rectifier test* Only a biker knows why a dog sticks his head out of a car window.

23-10-22, 06:44 AM	#10
Geodude Member Mega Poster Join Date: Jun 2009 Location: Durham Posts: 2,669	Re: Floppy clutch lever? Thanks for the link very useful ta __________________ Black naked 1999 sv650 which im trying to keep happy Custom paintwork *Saragon Customs* Spray painting *Electrical fault finding guide* and *Regulator rectifier test* Only a biker knows why a dog sticks his head out of a car window.

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